Wooden Magnetic Blocks and Method of Making Magnetic Blocks with Spherical Magnets

ABSTRACT

The Wooden Magnetic Blocks is a magnet housing unit for spherical magnets that enable a child to enjoy the unique properties of a spherical magnet while mitigating the possibility of swallowing the spherical magnet. The United States Consumer Product Safety Commission 16 C.F.R. Part 1501.2 states a small part is any object that fits into a specially designed test cylinder 2.25 inches (57.10 mm) long by 1.25 inches (31.70 mm) wide that approximates the size of the fully expanded throat of a child under three years old is banned because the small part presents a choking hazard. With that in mind, a magnet housing unit that is greater than 32 mm in diameter mitigates the possible choking hazard for magnets that are less than 32 mm in diameter. Additionally, the method of manufacturing magnetic blocks with spherical magnets comprise of symmetrical housing unit halves, that when coupled, contain a spherical magnet, which in turn makes the manufacturing process more efficient due to requiring fewer steps to complete the magnet housing unit; wherein the halves are produced from wood, it requires fewer milling steps than previous designs; wherein the halves are produced from an extrudable material, it only requires one injection mold. The final shape of the block may be formed either prior to or subsequent to machining and sealing of the magnet housing unit. Wherein the magnet housing unit for spherical magnets becomes Wooden Magnetic Blocks, which then enable a child to enjoy the unique properties of a spherical magnet while mitigating the possibility of swallowing the spherical magnet.

CROSS-REFERENCE TO RELATED APPLICATIONS

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STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

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REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPX

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BACKGROUND OF THE INVENTION

Children's building blocks are a well-known construction toy that helps develop a child's understanding of balance, construction, and design. Spherical magnets are a popular toy for both adults and children because the magnets can be arranged without the consideration to the north and south polarities found with conventional cylinder shaped magnets. However, there have been multiple documented cases where children were harmed or injured by swallowing magnets less than 32 mm in diameter. This invention utilizes a magnet housing unit, such as a wooden building block, that helps mitigate the possibility of a child swallowing a spherical magnet less than 32 mm in diameter and thus enables a child to enjoy and play with spherical magnets in a much safer format.

BRIEF SUMMARY OF THE INVENTION

Spherical magnets are a popular toy for both adults and children because the magnets can be arranged without the consideration to the north and south polarities found with conventional cylinder shaped magnets. However, magnets less than 32 mm in diameter are possible choking hazards for children. Magnets of that size or smaller are embedded in a magnet housing unit that has a diameter greater than 32 mm which mitigates the possibility of a child swallowing the small magnet. The Wooden Magnetic Blocks is a magnet housing unit for spherical magnets that enable a child to enjoy the unique properties of a spherical magnet while mitigating the possibility of swallowing the magnet.

The Method of Making Magnetic Blocks with Spherical Magnets is designed to be more efficient than any previous methods. This method comprises of symmetrical magnet housing unit halves, that when coupled, house a single spherical magnet. By making the halves symmetrical, fewer steps are required to complete the magnet housing unit; wherein the halves are produced from wood, it requires fewer milling steps than previous designs; wherein the halves are produced from an extrudable material, it only requires one injection mold. The final shape of the block may be formed either prior to or subsequent to machining and sealing of the magnet housing unit.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

FIG. 1 is an exploded view of a cube wooden block made in accordance with one embodiment of the invention.

FIG. 2 is an exploded view of a quarter circle wooden block made in accordance with one embodiment of the invention.

FIG. 3 is an exploded view of a twelve-sided (Dodecahedron) wooden block made in accordance with one embodiment of the invention.

FIG. 4 is a flow diagram of the process of making the magnetic wooden blocks in accordance with one embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1, 2, 3 are exploded views of a block made in accordance with one embodiment of the invention. In FIG. 1, 2, 3 the ultimate geometric shapes are a cube, quarter circle, and dodecahedron block, which are formed as a first half (102, 202, 302) and a second half (104, 204, 304).

For mass manufacturing, the method for the symmetrical halves can be formed in large groups with both non-extrudable material, such as wood, or extrudable material, such as plastic resin. However, hardwood is preferred due to the desired tactile properties for a Montessori-friendly children's toy.

For both non-extrudable and extrudable material designs, pockets (106, 206, 306) are defined in both the first half (102, 202, 302) and the second half (104, 204, 304) to receive the spherical magnet (108, 208, 308) and hold them internally.

The second half (104, 204, 304) that now possess an internal pocket is then oriented to become the bottom half of the block design. The spherical magnet (108, 208, 308) is then placed in the bottom half (104, 204, 304) of the block design. The first half (102, 202, 302) that now possess an internal pocket is then oriented to become the top half of the block design.

For the Wooden Magnetic Blocks design, the top half (102, 202, 302) and bottom half (104, 204, 304) are then coupled together along the internal surface. An adhesive such as wood glue may be used to achieve the coupling. The relatively large surface area of the internal surface enables a strong adhesion and disassembly of the blocks is unlikely. The preferred wood glue is the type that is commercially approved for indirect food contact such as Titebond II and Titebond III. The line of adhesion from the first half (102, 202, 302) and second half (104, 204, 304) is almost not detectable when appropriately grain matched. The blocks are then sanded with slightly rounded corners and edges. Finally, the blocks are painted with ASTM F963 and/or CPSIA tested and approved paint.

For the extrudable material block design, the top half (102, 202, 302) and bottom half (104, 204, 304) are then coupled together along the internal surface. The relatively large surface area of the internal surface enables a strong adhesion and disassembly of the blocks is unlikely. The preferred adhesive material is a resin-based adhesive that is commercially approved for indirect food contact. The line of adhesion from the first half (102, 202, 302) and second half (104, 204, 304) is slightly detectable even after polishing; however, disassembly of the block is unlikely. The extrudable material block design does not need surface painting since the color is defined by the extrudable material itself.

In accordance with one embodiment of the invention, the single spherical magnet (108, 208, 308) that is centrally housed in the magnet housing unit mitigates the possibility of a child swallowing a magnet that is less than 32 mm in diameter.

Additionally, Magnetic Wooden Blocks enables the children's toy block to magnetically attract to adjacent Magnetic Wooden Blocks without consideration to the magnetic polarity. The spherical magnets (108, 208, 308) may be Neodymium Iron Boron (Nd—FeB) magnets, which possess strong attraction properties to one another. This design allows young children that do not yet understand the polarity of magnets to construct structures that are not possible to sustain with simple non-magnetic blocks. 

1. As an embodiment of the invention, the inventor claims a magnet housing unit mitigates the possibility of a child swallowing a magnet that is less than 32 mm in diameter when the magnet housing unit diameter is 32 mm or greater; wherein the magnet housing units becomes Wooden Magnetic Blocks.
 2. As an embodiment of the invention according to claim 1, the inventor claims the Method of Making Magnetic Blocks with Spherical Magnets comprise of symmetrical magnet housing unit halves that contain a spherical magnet, which in turn makes the manufacturing process more efficient due to requiring fewer steps to complete the magnet housing unit; wherein the halves are produced from wood, it requires fewer milling steps than previous designs; wherein the halves are produced from an extrudable material, it only requires one injection mold.
 3. As an embodiment of the invention, the inventor claims the magnet housing unit, wherein the magnet housing units becomes Wooden Magnetic Blocks, is an apparatus for holding magnets that mitigate the possibility of a child swallowing a magnet that has a diameter less than 32 mm. 